GREENSTAR CAMRAY EXTERNAL 12/18, 18/25, 25/32 FLOOR STANDING EXTERNAL OIL FIRED CONDENSING BOILER USING BALANCED FLUE SYSTEM FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER CYLINDER THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY GB INSTRUCTION MANUAL INSTALLATION COMMISSIONING & SERVICING
INSTALLATION & SERVICING INSTRUCTIONS Programmer ON CH only SYMBOLS USED IN THIS MANUAL: Domestic hot water Programmer ON DHW only Central heating Programmer ON CH and DHW Room thermostat Cold water main supply Frost thermostat Electricity supply Wait time period PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
SAFETY & REGULATIONS CONTENTS IMPORTANT INFORMATION AND SYMBOLS 1 SAFETY PRECAUTIONS AND INSTALLATION REGULATIONS 3 APPLIANCE INFORMATION SAFETY & REGULATIONS APPLIANCE INFORMATION GENERAL INFORMATION 4 TECHNICAL DATA 5 LAYOUT & COMPONENTS 6 CLEANING PRIMARY SYSTEMS 7 MAINS SUPPLY 8 9 WATER SYSTEMS & PIPEWORK CONDENSATE PIPEWORK 10-11 12 PRESSURE RELIEF PIPEWORK 12 BOILER LOCATION & CLEARANCES 13 FLUE TERMINAL POSITIONS 14 BALANCED FLUE OPTIONS 15 INSTALLATION OIL SUPPLY PRE IN
SAFETY & REGULATIONS SAFETY PRECAUTIONS INSTALLATION REGULATIONS OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE: 4Extinguish any naked flames. 4Isolate the electrical supply. 4Isolate the fuel supply to the boiler. 4Rectify fault. HEALTH & SAFETY: The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
GENERAL INFORMATION STANDARD PACKAGE: 780mm 565mm A A - Floor standing oil fired condensing boiler for open vent and sealed domestic central heating and mains fed hot water. B - Literature pack. D - Hardware pack. E - 100mmØ services duct. 950mm APPLIANCE INFORMATION C - Condensate trap kit. B C D E Check List Item Qty Greenstar Camray External Installation/Servicing Instructions............1 Users Instructions .....................................................................................
TECHNICAL DATA DESCRIPTION UNITS 12/18 18/25 25/32 litres 23 23 21 Maximum static head metres 30 30 30 Minimum static head metres 1 1 1 mbar 26 52 69 bar 2.5 2.5 2.5 kg/hr 29 40 51 Fuel line (compression) mm 10 10 10 Return mm 22 22 28 Flow/optional open vent BSP 1 1 1 1/4 Drain/optional feed and expansion BSP 3/ 3/ Condensate (polypropylene) mm 21.5 21.5 21.5 AC...V 230 230 230 Frequency Hz 50 50 50 Max.
LAYOUT & COMPONENTS The diagram opposite excludes the top, front and RH side casing panels.
CLEANING PRIMARY SYSTEMS IMPORTANT: All the following Pre-Installation sections must be read and requirements met before starting boiler or flue installation. CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for t he use of wat er treatment with the appliance will invalidate the appliance warranty.
IMPORTANT: The appliance provides a permanent external electrical supply for servicing and must therefore be fed via a circuit breaker incorporating earth leakage protection. MAINS SUPPLY ELECTRIC SUPPLY: • Supply: 230V - 50Hz. • Cable: PVC insulated 0.75mm2 (24 x 0.2mm) temperature rated to 90°C. • Protection IP45. • External 5A fuse to BS 1362. • The appliance must be earthed. • Please refer to IEE regulations for cross bonding requirements.
A B C D E F G - Oil storage tank. - Isolating valve. - Oil strainer & water seperator. - Fire valve to BS 5410. - External casing. - Fire valve sensor. - Oil burner. H J K L M N OIL SUPPLY - Oil supply pipe. - Oil pump. - Full base (plastic tanks). - Non-return valve. - De-aerator. - Oil filter (16µm max filtration size) OIL SUPPLY : • This appliance is suitable for 28 second kerosene only, no other fuel must be used. • Plastic or steel tanks should be installed to BS 5410.
WATER SYSTEMS & PIPEWORK IMPORTANT: The boiler should not be allowed t o operat e wit h a ret urn temperature of less than 40°C when the system is up to operating temperature. TYPICAL OPEN VENT SYSTEM: PRIMARY SYSTEM PLASTIC PIPEWORK: • Do not use plastic pipework on sealed systems, *apart from underfloor heating correctly installed as detailed below. E S 1000mm min. 150mm max.
WATER SYSTEMS & PIPEWORK Water main supply Heating return Hose return Non return Non return valve valve Stop cock Temporary hose Auto air vent • Filling the system must comply with one of the methods shown opposite. • The filling point must be at low level and must never be a permanent direct fixing to the mains water supply. • Filling loops must be WRAS approved.
CONDENSATE & PRESSURE RELIEF PIPEWORK a C B CONDENSATE PIPEWORK: A D 75mm min. • The condensate pipework must fall at least 50mm per metre towards the outlet and should take the shortest practicable route and not exceed 3 metres outside the building. • The pipework must follow one of the options shown opposite: c C E C A A 450 min.
BOILER LOCATION & CLEARANCES 600mm WARNING: This appliance should not be installed where there is a potential for excessive ground water coverage. 2500mm FRONT 600mm This boiler is only suitable for installing externally at a suitable location onto a fixed permanent rigid surface c apable of supporting the boiler weight. There must be a sufficient hard standing around the appliance to allow for servicing.
FLUE TERMINAL POSITIONS Minimum dimensions of flue terminal positions for oil-fired appliances: • Flue terminals must be positioned to avoid combustion products entering into buildings. B(H) Directly below an opening, air brick, opening windows, etc 600mm • The flue must be fitted and terminated in accordance with the recommendations of BS5410. Horizontally to an opening, air brick, opening window, etc 600mm • The flue must not cause an obstruction.
BALANCED FLUE OPTIONS • The balanced flue is fitted to the rear or either side of the cabinet. REAR FLUE OUTLET A+C IMPORTANT: It is strongly recommended that the flue terminal faces away from walls to minimise the occurance of wetting. PRE INSTALLATION Plan view FRONT A - External horizontal flue kit Part No. 7 716 190 052 RIGHT HAND FLUE OUTLET A+B+C B - 90° inline elbow 80/125mm Part No. 7 716 190 034 Plan view C - Terminal guard (not included in flue kit) Part No.
IIMPORTANT: All the previous Pre-Installation sections must be read and requirements met before starting boiler or flue installation. UNPACKING THE BOILER LIFTING AND CARRYING PRECAUTIONS: • Lift only a manageable weight, or ask for help. 1 • When lifting or putting things down, bend the knees, and keep the back straight and feet apart. • Do not lift and twist at the same time. • Lift and carry objects close to the body. • Wear protective clothing and gloves to protect from any sharp edges.
All dimensions in mm 295 PIPEWORK & FLUE POSITIONS 259 Flue CAUTION: Ensure there are no pipes, electric cables, damp proof courses or other hazards before drilling. 259 Services 102 SAFETY: All relevant safety precautions must be undertaken. Protective clothing, footwear, gloves and safety goggles must be worn as appropriate. 793 Condensate 490 PRV PIPEWORK CONNECTIONS: 254 Flow/open vent 1” BSP 12/18, 18/25. 11/4” BSP 25/32.
WARNING: THIS APPLIANCE IS SERVICED AND REPAIRED EXTERNALLY. EXTERNAL EQUIPMENT OPERATED AT 230V SHOULD NOT BE INSTALLED, SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS. THIS APPLIANCE IS INSTALLED AND SERVICE EXTERNALLY TO THE PROPERTY, BUT THE ENGINEER MUST HAVE ACCESS TO THE INSIDE OF THE PROPERTY WHEN INSTALLING OR SERVICING THE APPLIANCE. BOILER INSTALLATION Note: The cabinet is not load bearing it only provides weather protection for the boiler inside.
IMPORTANT: REFER TO FLUE INSTALLATION MANUAL FOR MORE INFORMATION. INSTALLATION A - Air box rear. A1 - Tag. B - Air box rear gasket. C - Air box front. D - Retaining bracket. E - Terminal guard support. F - Air inlet cover. G - Flue terminal. H - 80mmØ Flue pipe. J - Air inlet outer section. K - Air inlet inner section. L - Inlet clamp. M - Stainless steel terminal guard (not supplied, Part No. 7 716 190 050). N - Accessory pack.
Side flue options: 6.0 4Lightly grease the 90° elbow seals with the solvent free grease supplied and fit the flue elbow to the flue cowl with the clamp (L) in place. 6.1 4Fit the air inlet inner section (K) to the elbow. 6.2 4Fit the air inlet outer section (J, not required if flueing to the right hand side) over the inner section (K), push through the panel so that the end of the tube is flush with the tag (A1) on the air box rear with one of the longer self tapping screws provided. 6.
COMBUSTION CHAMBER Combustion chamber: 14 Release retaining nuts and washers (A). 4 Remove combustion chamber access door (B). 24 Release screws (C) on either side and remove upper access door (D). 34 Ensure baffles (E) and baffle retainers (F), restrictor plates (G) and acoustic insulation insert (H) are correctly fitted for the boiler model as shown in the plan view opposite. For further information refer to the Baffle Arrangement Diagram on the last page at the back of this manual.
CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. PIPEWORK CONNECTIONS A - C (Return pipe) located at the side of the secondary heat exchanger A Flow/open vent 1” BSP on 12/18, 18/25 (11/4” BSP on 25/32 models) B - Primary drain/feed 3/4” BSP C - Return 22mm Ø copper (28mm Ø on 25/32 models) D - Fixing point for optional return oil pipe.
PIPEWORK CONNECTIONS G - Flue manifold condensate outlet H - Condensate outlet (21.5mmØ) - supplied I - Condensate pipe - not supplied J - K - Condensate trap Condensate trap fixing bracket - supplied H J K I INSTALLATION G CONDENSATE CONNECTION: 4The condensate trap ( J ) must be installed onto the bracket (K) supplied. 4Measure condensate pipe (H) mark and cut square to length required. 4Fit sealing washer inside condensate pipe nut and connect to the flue manifold outlet (G). 4Connect 21.
OIL BURNER & PUMP CAUTION: ISOLATE THE OIL & WATER MAINS SUPPLY BEFORE STARTING ANY W OR K AN D OB S E RVE ALL R E LE VANT SAFETY PRECAUTIONS. OIL BURNER: 14 Check the nozzle (A) and electrode (B) settings are correct as shown opposite. 4 Ensure nozzle (A) is aligned centrally within the combustion head (C). 4 Inspect for any visible defects. 2 IMPORTANT: Before removing or fitting a nozzle (A), loosen screw (D) and move the electrodes (B) forward.
REFITTING COMPONENTS 2 14 Align burner combustion head into boiler collar. 4 Locate the burner retainer (A) over the threaded lug on the collar (B), push the burner firmly onto the flange and secure in place with the retaining nut (C). Tighten sufficiently but do not overtighten. 4 Check that the burner is seated correctly on its mounting flange and that the oil pipe/s are not trapped in front of or underneath the burner. H G 4 Refit the deflector plate (D) and secure with screws (E).
ELECTRICS A DANGER - 230V: ISOLATE THE MAINS ELECTRICITY SUPPLY BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. = EARTH 1 = PERMANENT LIVE B = NEUTRAL = SWITCHED LIVE IMPORTANT: OBSERVE ELECTRONIC STATIC DISCHARGE PRECAUTIONS. DO NOT TOUCH THE PCB CIRCUITS. A WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS.
ELECTRICS 230V STANDARD WIRING DIAGRAM: Key to components: A - EARTH STUD. = EARTH • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE B - BOILER MANUAL RESET THERMOSTAT. C - FLUE MANUAL RESET THERMOSTAT. D - HIGH LIMIT THERMOSTAT. E - TERMINAL CONNECTOR BLOCK. F - CONTROL THERMOSTAT. G - BURNER SOCKET. H -BURNER PLUG. J - BURNER CONTROL BOX. K - FROST THERMOSTAT. L - MODE SWITCH. M -DEMAND INDICATOR. 1 2 3 A E N - SERVICE CONNECTION.
ELECTRICS O • = EARTH • = PERMANENT LIVE • = NEUTRAL • = SWITCHED LIVE REMOTE 2 OR 3 PORT VALVE CONTROL SET USING REMOTE PROGRAMMER: Key to components: O - REMOTE JUNCTION BOX (10-way) to connect the following (refer to manufacturers instructions): 4Mains wiring 230V 50Hz, fed via a circuit breaker incorporating earth leakage protection. 4Hot water tank thermostat. 4Room thermostat. 4System water valves. 4Circulating pump. 4External programmer.
PRE-COMMISSIONING CHECKS APPLIANCE CAUTION: ISOLATE THE MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 14Check that the service and water pipes are connected correctly. 4 Check that all unused sockets are capped off. 24 Check that the oil supply is 28 sec kerosene and that the pipework is connected correctly to the oil pump. 1 3 4Turn on the main oil supply valve at the tank, check the oil supply pipework and connections. Rectify any leaks.
FILLING THE SYSTEM 1 14 Open all system and radiator valves. 4 Turn on the water main stop cock. 4 Open vented systems only: 4 Turn on the water to the system feed and expansion cistern and allow the system to fill. 24 Sealed systems only: 4 Check and if required, adjust the expansion vessel pressure using the Schraeder type valve (C). 2 4 Fill the system to between 1 and 2 bar pressure via a WRAS approved filling link.
STARTING THE APPLIANCE 1 IMPORTANT: Never run the appliance when the appliance/system is unpressurised (sealed systems) or empty. 14Check the oil supply is correctly fitted and in good working order before turning on the oil supply valves to the boiler. on service max flue reset boiler reset GREENSTAR CAMRAY EXTERNAL RIELLO C B 4Single pipe gravity feed systems: 4Disconnect the flexible oil pipe and open the isolating valve to discharge the oil into a suitable container.
STARTING THE APPLIANCE 24 Remove plastic cover from the burner casing. 4 Fit a suitable pressure gauge to port (A) on the oil pump. 4 Adjust the air shutter (L) and pump pressure (B) as shown in the table opposite. The burner should ignite following a pre-ignition period of approx. 15 seconds. 4 If changing the burner output, check the position of the air damper disc is correct to the output as shown in the table below. NOTE: For 25/32 appliance see following page.
STARTING THE APPLIANCE On 25/32 Appliances: To achieve the mimimum output of 25kW from the 25/32 RDB 2.2 it is necessary to remove the air guide (D) from the burner. For any other required output the air guide must remain in place. A 4Disassemble the burner, removing the red plasic cover, flexible air hose and air intake manifold (A). 4Remove the fan housing (B) by undoing the four securing screws. 4Remove the two screws (C) securing the plastic air guide.
STARTING THE APPLIANCE 1 Central heating: 14Open all radiator valves. 4Set room thermostat to maximum. 4Set programmer to ON for CH, OFF for DHW (if applicable). 4Turn the thermostat control (B) to ‘max’. on service max flue reset boiler reset B The demand indicator (A) should illuminate and the burner should be ON with the circulating pump.
WATER TREATMENT 1 IMPORTANT: Debris from the system can damage the boiler and reduce efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance warranty. B FLUSHING (Central Heating): 14Switch off the boiler. 4Open vented systems only: turn off the water to the system header tank. 4Open all radiator valves/drain cocks (B) and drain the system while the appliance is hot. 4Close drain cocks (B).
FINISHING COMMISSIONING APPLIANCE A 1 14 Refit the top panel and press down to compress the seal when fitting the securing screws (A). 24 Push the front panel (B) up behind the top panel and push in at the base to secure with the easy grip screws (C). 2 B C D C Handover: 4Complete the Guarantee Registration Card, Combustion Record (page 47) and a CD11 or an equivalent commissioning form.
INSPECTION AND SERVICE CAUTION: ISOLATE THE WATER, ELECTRICITY AND OIL MAINS SUPPLIES BEFORE STARTING ANY WORK AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS. 2 DO NOT USE PRESSURE WASHERS OR STEAM CLEANERS ON THIS APPLIANCE OR ITS CABINET. 1b on WARNING: EXTERNAL EQUIPMENT OPERATED AT 230 VOLTS SHOULD NOT BE SERVICED OR REPAIRED UNDER ADVERSE WEATHER CONDITIONS A service C B Routine servicing: To assist efficient boiler operation, the following should be carried out at least once a year.
INSPECTION AND SERVICE 1 Clean the Burner: 4Remove the air intake cover (A) and clear any debris from the air intake and air damper. 4Disassemble the burner to allow access to the fan impeller. 4Check the condition of the gaskets between these parts and replace if necessary. 4Note the position of the air damper adjustment and check the air damper moves freely. 4Clean both sides of the fan impeller and remove any debris from the burner housing. 4Check that the impeller rotates freely.
INSPECTION AND SERVICE External oil filter: 4Remove the paper element from the external oil filter and replace it. If the filter contains a washable element, thoroughly clean in kerosene and reassemble into the filter. Clean the boiler: A Manifold access: 4Remove top cover by releasing the screws (A) at each corner and lift free. 4Release screws (B) to remove the flue manifold access cover (C) and clear any debris. 4Check the condensate route (D) is clear and clean the condensate trap and pipework.
INSPECTION AND SERVICE I I Re-commission the burner: 14 Align burner combustion head into boiler collar. 2 4 Locate the burner retainer (A) over the threaded lug on the collar (B), push the burner firmly onto the flange and secure in place with the retaining nut (C). Tighten sufficiently but do not overtighten. 3 4 Check that the burner is seated correctly on its mounting flange and that the oil pipe/s are not trapped in front of or underneath the burner.
SHORT PARTS LIST 12/18 2 1 1 Burner - Riello RDB 1 12/18 Part Number: 8 716 111 951 0 3 4 7 7a 5 6 8 9 2 Combustion head - LD2X SH12/18 Part Number: 8 716 112 731 0 3 Control box 535 RSE/LD Part Number: 8 716 109 203 0 4 Photocell Part Number: 8 716 109 193 0 5 Ignition electrode Part Number: 8 716 109 183 0 6 Motor Part Number: 8 716 109 186 0 7 Oil pump - Riello RDB Part Number: 8 716 109 182 0 7a Pump coupling Part Number: 8 716 109 245 0 8 Flexible oil line kit Part Number: 8 716 106 346 0 9
SHORT PARTS LIST 18/25 2 1 1 Burner - Riello RDB 2.
SHORT PARTS LIST 25/32 2 1 3 7 4 7a 1 Burner - Riello RDB 2.
PROBLEM CAUSE REMEDY CF - Flue draught incorrect CF - Check flue draught Combustion settings incorrect Set up as in installation instructions Faulty nozzle Replace nozzle FAULT FINDING LOCKOUT: Pulsation on start Intermittent lockout Burner motor fails to operate Flame detection fault Incorrect CO2 No oil from nozzle Bad electrical connection Check control box/electrical connections Intermittent flame detection fault See flame detection fault CF down draught CF Extend flue or fit an ant
PROBLEM CAUSE REMEDY Pump noise from air in pump or worn pump Bleed air from pump or replace pump Worn motor bearings Replace motor Fan out of balance Replace fan Faulty boiler thermostat Replace if necessary Short circuit boiler thermostat Take out of circuit to check Thermostat bulb not fully home in pocket Ensure bulb is pushed fully home No primary water circulation Check system / circulating pump FAULT FINDING FAULTY BOILER OPERATION: Noisy operation Boiling Short Cycling Correct b
INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 8 716 112 700a (02.
BOILER MODEL OIL BOILER COMBUSTION RECORD COMMISSIONING ENGINEER COMPANY NAME: ADDRESS: ENGINEERS NAME: SIGNATURE: DATE: FOR ALL BOILERS CONFIRM THE FOLLOWING SERIAL No. COMBUSTION CHECKS PUMP PRESSURE (PSI): CO2 %: SMOKE READING: F.G.
SERVICE 2 DATE SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS psi CO2%: YES NO FLUE PRESSURE: SERVICE 4 DATE SERVICE 3 DATE psi CO2%: YES NO FLUE PRESSURE: ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS SIGNATURE SIGNATURE ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No. PUMP PRESSURE: NOZZLE CHANGED? F.G.T. °C COMMENTS ENGINEER NAME COMPANY NAME TEL No. OFTEC REG No.
NOTES NOTES 49 NOTES INSTALLATION & SERVICING INSTRUCTIONS FOR WORCESTER GREENSTAR CAMRAY EXTERNAL 12/18-18/25-25/32 8 716 112 700a (02.
BAFFLE ARRANGEMENT DIAGRAM 12/18 MODEL SHOWN BAFFLE ACCESS DOOR ACOUSTIC INSULATION INSERT (All models) Remove last. Refit first. RESTRICTOR PLATE (2 for 12/18 models, 1 for 18/25 models) Remove and fit through baffle access door. 12/18 fitted into tubes 2 & 3. 18/25 fitted into tube 2. 1 BAFFLE RETAINER Remove and fit through baffle access door.
If in the unlikely event the boiler does not give complete satisfaction, before calling for a service engineer, the installer should check the following:General checks 1. Is the mode switch in boiler mode (indicator on)? 2. Is there 230V across the boiler live and neutral terminals? 3. Is there 230V across the terminals 1 and N? 4. Is the polarity correct? (230V across live and earth, 0V across neutral and earth) 5. Is the air bled from the primary system? 6. Is the air bled from the oil supply? 7.
Important addendum Secondary Heat Exchanger Replacement Seal These instructions must be read in conjunction with the installation & servicing instructions supplied with the appliance. For use on appliances: Greenstar Heatslave, Greenstar Danesmoor & Greenstar Camray Condensing oil fired boiler ranges. CAUTION: Isolate the water, electricity and oil mains supplies before starting any work and observe all relevant safety precautions.
GREENSTAR CAMRAY EXTERNAL EXTERNAL OIL FIRED CONDENSING BOILER USING BALANCED FLUE SYSTEM FOR FULLY PUMPED OPEN VENT OR SEALED CENTRAL HEATING SYSTEMS AND DOMESTIC HOT WATER WATER CYLINDERS For use with the following Greenstar oil fired appliances: Greenstar Camray External 12/18, 18/25, 25/32 THE APPLIANCE IS FOR USE WITH 28 SECOND KEROSENE ONLY GB USER INSTRUCTIONS & CUSTOMER CARE GUIDE
CONTACT INFORMATION USER INSTRUCTIONS & CUSTOMER CARE GUIDE Worcester, Bosch Group: PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE OPERATING YOUR APPLIANCE. Service call centres: UK TEL: 08457 256206 FAX: 08457 757536 SCOTLAND ONLY FAX: 01506 441687 Other enquiries: TEL: MAIN RECEPTION: 01905 754624 TECHNICAL: 08705 266241 SPARES: 01905 752571 LITERATURE: 01905 752556 SALES: WEBSITE: FAX: 754619 01905 752640 www.worcester-bosch.co.
ENERGY SAVING TIPS ON ENERGY SAVING USING YOUR APPLIANCE 6 ENERGY SAVING 7 7 7 8 9 10-11 12 13 14 GUARANTEE YOUR GUARANTEE GUARANTEE REGISTRATION 15 16 NOTES MAINTENANCE MAINTAINING YOUR APPLIANCE FAULT FINDING FAULT OR BREAKDOWN MAINTENANCE USING YOUR APPLIANCE CONTROLS OPERATING THE APPLIANCE Switching the boiler on/off Setting the radiator temperature Controlling central heating Frost protection Fault conditions 2 3 4-5 GUARANTEE INTRODUCTION SAFETY PRECAUTIONS EXCELLENCE COMES AS STANDARD
INTRODUCTION SAFETY PRECAUTIONS OIL SMELLS, LEAKS OR FUMES FROM THE APPLIANCE: 4 Extinguish any naked flames. 4 Open windows and doors. 4 Switch off the appliance electricity supply. 4 Isolate the fuel supply to the boiler. 4 Contact installer/service engineer. HEALTH & SAFETY: The appliance contains no asbestos and no substances have been used in the construction process that contravene the COSHH Regulations (Control of Substances Hazardous to Health Regulations 1988).
Thank you for purchasing a Greenstar Camray oil fired condensing boiler from Worcester, Bosch Group. The company prides itself on manufacturing boilers to the strictest quality control standards throughout every stage of production. INTRODUCTION EXCELLENCE COMES AS STANDARD Worcester, Bosch Group has led the field in innovative appliance design and performance for more than 40 years. This heritage means all products are of exceptional quality and proven reliability.
INTRODUCTION GENERAL INFORMATION Read these instructions carefully to get the best from your appliance. CENTRAL HEATING SYSTEMS: During the first few hours of operation of the central heating system, check that all radiators are being heated at an even rate. If the top of a radiator is at a lower temperature than the bottom then it should be vented by releasing air through the venting screw at the top of the radiator. Ask your installer to show you how this is done.
GENERAL INFORMATION WARNING: External equipment operating at 230 Volts must not be serviced or repaired during adverse weather conditions. 600mm INTRODUCTION INSTALLATION & SERVICING CLEARANCES 600mm FRONT Do not use pressure washers or steam cleaners on this appliance or cabinet. 2500mm FUEL: This appliance is designed to use 28 second kerosene, no other fuel must be used. BOILER LOCATION: WARNING: BASE 600mm min.
CONTROLS D C E on service USING YOUR APPLIANCE max flue reset A boiler reset GREENSTAR CAMRAY EXTERNAL B To remove the front panel, unscrew the “easy grip” screws on each side of the base of the front panel. The panel will then drop down and can be removed (see illustration below). A Reset button - flue thermostat (behind front panel). B Reset button - heating (behind front panel). C Temperature control. D Boiler mode indicator. E Mode switch.
OPERATING THE APPLIANCE SWITCHING THE BOILER ON/OFF: 4 Check the mode switch is in boiler mode with the indicator illuminated. 4 Check the programmer/timer is correct and it is set to ON. 4 Set the room thermostat to the desired setting. USING YOUR APPLIANCE 4 To switch on the boiler; turn on the water, oil and electricity supply to the boiler. 4 Open and set thermostatic radiator valves as required. 4 Turn the boiler water temperature control to the required setting.
OPERATING THE APPLIANCE FROST PROTECTION: 4 A frost thermostat is fitted to the appliance to protect the appliance and system from the risk of freezing. USING YOUR APPLIANCE 4 The boiler mode indicator light MUST be illuminated for the frost protection to operate. In the unlikely event that there is no hot water or heating, remove the front panel and check for lockout or other fault conditions. Check page 9 for fault conditions.
1 ACCESSING CONTROLS: OPERATING THE APPLIANCE FAULT CONDITIONS: The ‘Boiler mode’ and ‘Lockout’ lights can indicate some basic fault conditions. 4 Unscrew the easy grip screws on the bottom of the front panel. The panel will drop down and can be removed. 2 NORMAL OPERATION: 2 Normal operation: on service max flue reset boiler reset GREENSTAR CAMRAY EXTERNAL The appliance is in boiler mode, with a demand for heat from the controls.
TIPS ON ENERGY SAVING Heating economically: The boiler is designed to provide a high level of comfort while keeping oil consumption and the resulting environmental effect as low as possible. The central heating control on the boiler should be set as low as possible while still maintaining a comfortable room temperature. ENERGY SAVING The temperature of each room can be set individually using the thermostatic radiator valves (except the primary room with the room thermostat).
TIPS ON ENERGY SAVING Room thermostats: Reducing the setting of the room thermostat by 1°C can reduce fuel consumption by up to 10%. New control systems: Upgrade your heating control system with the latest equipment available. The minimum level of control for a heating system is a programmer/timer, interlocking room thermostat and thermostatic radiator valves. More often than not radiators will be sited underneath a window, so the warm air from the radiator heats the colder incoming air from the window.
MAINTAINING YOUR APPLIANCE Your new appliance represents a long term investment in a reliable, high quality product. In order to realise its maximum working life and to ensure it continues to operate at peak efficiency and performance, it is essential that servicing and maintenance checks are performed at least once a year by a competent person. If you would like to know more about servicing options from Worcester, Bosch Group please visit www.worcester-bosch.co.uk.
Problem Cause Remedy Desired room temperature is not reached Thermostatic radiator valve(s) set too low Increase thermostatic radiator valve setting(s) Room thermostat set too low Increase room thermostat setting Temperature control set too low Increase temperature control setting Air trapped in heating system Bleed radiators; if fitted to a sealed system recharge heating system Desired room temperature exceeded by large amount Radiators are too hot Turn down thermostatic radiator valves / roo
FAULT OR BREAKDOWN circumstances this will be from 1 to 3 working days (excluding weekends) for priority breakdown situations (no hot water and/or heating). This appliance is supported in the UK by Worcester, Bosch Group, part of BBT Thermotechnology UK Ltd. Specialist factory trained Service Engineers are available to attend in the unlikely event that a breakdown occurs on this appliance.
YOUR GUARANTEE This appliance is guaranteed against faulty materials or workmanship for a period of 24 calendar months (60 months for the primary heat exchanger) from the date of installation subject to the following conditions: 4 That during the period of this guarantee any components of the unit which are proved to be faulty or defective in manufacture will be exchanged or repaired free of material charges and free of labour charges if repaired directly by BBT Thermotechnology UK Ltd.
GUARANTEE REGISTRATION You should complete and return the postpaid Guarantee Registration Card within 30 days of installation. Returning your card will register you as the owner of your new appliance and will assist us in maintaining an effective and efficient customer service by establishing a reference and permanent record for your boiler. This does not affect your statutory rights. GUARANTEE For your own record: Model Serial No.
NOTES NOTES GREENSTAR CAMRAY EXTERNAL 12/18 - 18/25 - 25/32 8 716 112 711a (02.
USER INSTRUCTIONS & CUSTOMER CARE GUIDE EXCELLENCE COMES AS STANDARD Worcester, Bosch Group Cotswold Way, Warndon, Worcester WR4 9SW. Tel. 01905 754624 Fax. 01905 754619 www.worcester-bosch.co.uk Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Ltd. 8 716 112 711a (02.
